/ Marley MC Fluid Cooler / User Manual uk_07-1185C
Contents Note This manual contains vital information for the proper installation and operation of your fluid cooler. Carefully read the manual before installation or operation of the fluid cooler and follow all instructions. Save this manual for future reference. Fluid Cooler Location.............................................................................. 5 Fluid Cooler Shipment............................................................................. 6 Receiving Fluid Cooler......................
Preparation The Marley MC Fluid Cooler purchased for this installation represents the current state of the art in counterflow, forced draft fluid cooler design. Thermally and operationally, it is the most efficient fluid cooler of its class. These instructions—as well as those offered separately on motors, fans, float valves, pumps, etc.—are intended to assure that the fluid cooler serves you properly for the maximum possible time.
Preparation Note Those are only some of the safety issues that may arise in the design process. SPX strongly recommends that you consult a safety engineer to be sure that all safety considerations have been addressed. Several options are available that may assist you in addressing some of these personnel safety concerns, including: • Distribution level access platform with handrail system around the perimeter of the platform with a ladder for access to the platform.
Installation Shipment Unless otherwise specified, the MC Fluid Cooler ships by truck (on flat bed trailers), which lets you receive, hoist, and install the tower in one continuous operation. Single-cell coolers ship on one truck. Multicell fluid coolers, depending on their size, may require more than one truck. Responsibility for the condition of the fluid cooler upon its arrival belongs to the trucker—as does the coordination of multiple shipments, if required.
Installation Fluid Cooler Installation Note These installation instructions are intended to help you prepare before your fluid cooler arrives. If discrepancies exist between these instructions and those shipped with the fluid cooler, the instructions shipped with the fluid cooler will govern. 1. Prior to placement of the fluid cooler, confirm that the supporting platform is level, and that the anchor bolt holes are correctly located in accordance with Marley drawings. 2.
Installation 6. Attach process fluid supply and return piping to the coil. Standard field piping connection is an NPT male connection at the coil. A flanged connection requires a gasket between the fluid cooler and the fluid supply piping. Caution For welded connections protect adjacent areas from excessive heat and sparks or damage may occur. 7. Wire motor(s) and recirculation pump(s) in accordance with wiring diagram.
Installation When using a two-speed starter: • Motor rotation must be the same at slow speed and high speed. • Single winding motor requires a starter with a shorting contactor. • Two-winding motor requires a starter without a shorting contactor. • All two-speed starters must have a 20 second time delay relay when switching from high speed to low speed. • Do not start the motor more than six times per hour (each low speed start and each high speed start count as one start).
Installation speeds. To benefit from these advantages, it is important that the drive be installed correctly. Marley supplies VFD and VFD controls specifically designed for our cooling products. If you have purchased a Marley VFD and/or controls package, please follow the instructions in the User Manual for that system. Most VFD problems can be avoided by purchasing the Marley drive system. If you are installing a VFD other than the Marley drive, please refer to that drives installation manual.
Installation Mechanical Equipment: Warning Warning Warranty is void if the fluid cooler is operated at speeds which cause damaging vibrations to the tower and associated equipment. When utilizing a variable frequency drive, the fluid cooler must be tested across the full range of speeds and checked against CTI guidelines for excessive vibration. Speed ranges not meeting these guidelines must be locked out in the VFD.
Operation Fluid Cooler Start-Up Warning Among other sources, outbreaks of Legionnaires’ Disease have reportedly been traced to cooling towers and fluid coolers. Maintenance and water treatment procedures that prevent amplification and dissemination of Legionella and other airborne bacteria should be formulated and implemented BEFORE systems are operated and continued regularly thereafter to avoid the risk of sickness or death. Water System: 1.
Operation the fluid cooler fan, execute one of the two alternative biocidal treatment programs described in the following: • Resume treatment with the biocide which had been used prior to shutdown. Utilize the services of the water treatment supplier.
Operation 2. Air wet-bulb temperature: Cold process fluid temperature will also vary with the wet-bulb temperature of the air entering the fluid cooler. Reduced wet-bulb temperatures will result in colder process fluid temperatures. However, the cold process fluid temperature will not vary to the same extent as the wet-bulb. For example, a 11°C reduction in wet-bulb may result in only a 8°C reduction in cold process fluid temperature. 3.
Operation normal fan and motor sizes utilized on MC Fluid Coolers, anticipate that approximately 4 to 5 starts per hour are allowable. If your fluid cooler is equipped with a two-speed motor(s), you will enjoy greater opportunity for process temperature control. When the process fluid temperature becomes too cold, switching the fan to half-speed will cause the cold process fluid temperature to rise— stabilizing at a temperature a few degrees higher than before.
Operation Caution If the minimum allowable cold process fluid temperature is established at or near minimum heat load, it should be safe for all operating conditions. Having established the minimum allowable cold water temperature, maintaining that temperature can be accomplished by fan manipulation, as outlined in Item 4 under Fluid Cooler Operation. 2. A fan operating in a forced-draft tower is subject to the risk of freezing.
Operation Warning Caution Warning Basin heaters systems will not prevent the coil from freezing. Unless some means of freeze prevention is incorporated into your system, the tower basin and exposed pipework should be drained at the beginning of each wintertime shutdown period. If fluid cooler basin is drained, verify that all basin heaters have been shut off either by automatic cutoff or disconnect switch.
Operation Water Treatment and Blowdown Maintaining Water Quality: The steel used in MC Fluid Cooler's has been galvanized with a heavy zinc coating averaging 2.0 mils in thickness. Other materials used (PVC drift eliminators, bearing, belts) are selected to offer maximum service life in a “normal” fluid cooler environment, defined as follows: Recirculating water with a pH between 6.
Operation Fluid Cooler Cleaning: Warning Any evaporative-type fluid cooler must be thoroughly cleaned on a regular basis to minimize the growth of bacteria, including Legionella Pneumophila, to avoid the risk of sickness or death. Service personnel must wear proper personal protective equipment during decontamination. Do NOT attempt any service unless the fan motor is locked out.
Operation centrations. The following table shows the minimum amount of blowdown (percent of flow) required to maintain different concentrations with various cooling ranges*: Cooling Range Number of Concentrations 1.5X 2.0X 2.5X 3.0X 4.0X 5.0X 6.0X 3°C .78 .38 .25 .18 .11 .08 .06 6°C 1.58 .78 .51 .38 .25 .18 .14 9°C 2.38 1.18 .78 .58 .38 .28 .22 11°C 3.18 1.58 1.05 .78 .51 .38 .30 14°C 3.98 1.98 1.32 .98 .64 .48 .38 Multipliers are based on drift of 0.
Maintenance Belt Tensioning The belts are adjusted by means of a hinged base with tensioning bolts accessible through the access panel/fan guards. Check tension frequently during the first 24-48 hours of run-in operation. To properly adjust the belt tension, position the fan motor so that moderate pressure on the belt midway between the sheaves will produce a 1⁄2" deflection. Overtensioning shortens belt and bearing life. Keep belts free from foreign material which may cause slipping.
Maintenance Included with this instruction packet are separate User Manuals on each major operating component of the tower, and it is recommended that you read them thoroughly. Where discrepancies may exist, the separate User Manuals will take precedence.
Maintenance Semi-Annually: Clean and disinfect fluid cooler with biocides. Systems with biofouling, high general bacterial counts, or positive cultures of legionella may require additional cleaning. Refer to “Fluid Cooler Cleaning” section—page 19. Consult your water treatment expert as to prudent biological evaluation testing. Annually: Relubricate motor(s) according to the manufacturer’s instructions. Check the belt tension and condition.
Maintenance Fluid cooler framework: Check structural bolted connections and tighten as required. Fans: Check fan assembly bolting and tighten as required. Use torque values prescribed in the Fan User Manual. Fans shaft bearings: Lubricate fan shaft bearings at close of each operating season—see page 22. Electric motors: Clean and lubricate motor at close of each operating season (refer to motor manufacturer’s recommendations.) Check motor anchor bolts and tighten as required.
Maintenance SPX Cooling Technologies Services Our interest in your MC Fluid Cooler does not end with the sale. Having conceived, designed, and manufactured the most reliable and longestlasting fluid cooler of its class, we want to make sure that you gain the maximum possible benefit from its purchase.
Maintenance Schedule Maintenance Service Inspect General Condition and Operation Monthly Semi-annually Seasonal Startup or Annually x x Mechanical–motor, pump, fan and drive mechanism x x Makeup valve (if equipped) x x Inspect for unusual noise or vibration x x Air inlet x x PVC drift eliminators x x Distribution system and nozzles x x Collection basin x x Fan and pump motor exterior x x Observe Operation of: Inspect and Clean: Coil surface x Check: Collection water basin l
Additional Services Increased load requirements: MC Fluid Coolers are designed so that cells of either equal or unequal capacity can be added in the future. This allows you to compensate for the load increases that normally occur with the replacement or addition of production equipment—and still retain continuity with respect to your fluid cooler system. Fluid cooler rebuilding: SPX routinely rebuilds and upgrades fluid coolers and cooling towers of all materials and manufacture.
Troubleshooting Trouble Cause Remedy Check power at starter. Correct any bad connections between the control apparatus and the motor. Power not available at motor terminals Check starter contacts and control circuit. Reset overloads, close contacts, reset tripped switches or replace failed control switches.
Troubleshooting Trouble Unusual fan drive vibration Fan noise Belt squeal or chirping Scale or foreign substance in circulating water system Cold water temperature too warm. See "Fluid Cooler Operation." Excessive drift exiting fluid cooler Water leaking from fan scroll Cause Remedy Loose bolts and cap screws Tighten all bolts and cap screws on all mechanical equipment and supports. Worn fan shaft bearings.. Check fan shaft endplay. Replace bearings as necessary.
SPX COOLING TECHNOLOGIES UK Ltd GREGORY’S BANK | WORCESTER WR3 8AB, UNITED KINGDOM | 44 (0) 1905 720 200 | info.uk@spx.com | spxcooling.com In the interest of technological progress, all products are subject to design and/or material change without notice.
